Printed spacecraft separation system

ABSTRACT

A spacecraft coupling system includes a locking component that can be deformed and placed into a stable state that locks one component into a mating component, and can easily be released from the deformed state, decoupling the two components. The locking component may include a central ring, a plurality of leaf elements arranged at the perimeter of the locking component, and a plurality of fins that extend outward from the ring to the plurality of leaf elements. A rotation of the ring element while the component is held stationary causes the fins to urge the leaf elements toward the receiving surface areas and to subsequently tension the leaf elements against surfaces on the mating component. To reduce cost and complexity, the locking component comprises a metal, such as titanium, that can be formed using an additive manufacturing process, commonly termed a 3-D printing process.

This application is a Divisional of U.S. patent application Ser. No.14/506,588 filed 3 Oct. 2014, which is incorporated by reference herein,and claims the benefit of U.S. Provisional Patent Application61/887,616, filed 7 Oct. 2013.

BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates to the field of mechanical connectors, and inparticular to connector assemblies for spacecraft stage separationsystems, such as satellite and missile systems.

Transport systems, such as rockets that transport satellites into space,vessels that transport submerged sections of ocean structures such asoil platforms, and the like, require a means for securely fasteningdifferent items together for transport, and reliably and easilyunfastening the items for deployment. Multi-stage rockets also require ameans for fastening the stages together, and reliably unfastening thestages as each stage is spent.

A variety of devices have been developed to secure two items togetherwhile also allowing the items to be separated quickly and reliably. Inthe aerospace industry, traditional connection devices include bolts andbands that can be severed. Bolts are used to fasten the two itemstogether, and an explosive charge is typically used to sever the boltsat the proper time, thereby unfastening the two items. Depending uponthe application, supplemental devices such as springs may be used tourge the two items apart when the bolts are severed. To assure areliable separation, the number of bolts used to fasten the two items iskept to a minimum; this results in load points at the bolts far inexcess of the load imposed by a distributed fastening system.

Belt structures are commonly used to provide for a distributed load. Abelt structure that is commonly employed to fasten items together is a“V-band”, typified by U.S. Pat. No. 4,715,565, incorporated by referenceherein. The V-band includes a tension belt for securing a plurality ofretainers against camming surfaces on flange members on separablespacecraft component parts. A typical V-band embodiment consists of anupper ring attached to the payload, a lower ring attached to the launchvehicle, and a clampband that is circumferentially tensioned to theflanges of the upper and lower rings. The clampband is conventionallytensioned by bolts, and explosive bolt cutters are used to sever thebolts to release the tension.

For V-bands to work properly, the tension required in the clampband isrelatively high (about 3800 pounds for a 38 inch diameter; 6800 poundsfor a 66 inch diameter), requiring radial stiffeners in the rings. Thesudden release of this stored energy generates high shock, and imposesadditional requirements on the means used to retain the fast movingclampband and clamps after separation. Because of the high tensionrequirements, the combined weight of the belt, clamps, and supplementalrequired devices is substantial (as much as 25 pounds for a 38 inchdiameter V-band structure). The high tension requirements of V-bandsoften require specialized tools and instruments to tension the band. Thehigh tension and high release shock effects also limit the reliable lifeof the components, thereby limiting the amount of testing that can beapplied to the components that are actually flown.

Another structure that is commonly used to provide for an easilyseparable connection is an explosive frangible joint, as typified byU.S. Pat. Nos. 4,685,376 and 5,390,606. An explosive detonating cord isplaced within a contained space that forms the frangible joint betweenthe two items. Separation is achieved by detonating the cord within thecontained space, forcing a rapid crack propagation through the frangiblejoint. Although the weight of an explosive frangible joint is less thanthat of an equivalent sized V-band, it is still substantial (as much as17 pounds for a 38 inch diameter joint). The destructive nature of thisseparation system precludes testing of the joints that are actuallyflown.

In 1999, Planetary Systems Corporation introduced a spacecraftconnection system (the “Lightband”) that is light weight, does not useexplosives, does not impart a substantial shock to the connected itemsupon separation, and is non-destructive, allowing for repeated useduring testing prior to launch.

As detailed in U.S. Pat. Nos. 6,227,493 and 6,343,770, each incorporatedby reference herein, and as illustrated in FIGS. 1A and 1B, theLightband comprises a first component 110 having a plurality of leafelements 115 with protrusions, and a second component 120 havingrecesses 125 for receiving the leaf element protrusions. The protrusionsof the leaf elements are secured within the recess by a retaining band,which may be a compressed band, or in an alternative embodiment, anexpansion band; the protrusions and recess are formed so as to provide aload and torque bearing surface that requires minimal tension on thetensioned band, or minimal compression on the expansion band. Electricmotors 150 are used to transition between a lock state and a releasestate, each state being mechanically stable (unstressed). When the bandis released, springs 130 in the hinge of the leaves 115, or other means,urge the leaves 115 away from the mating surfaces 125, thereby allowingfor the separation of the connected items. Springs 140 are also used tourge the second component 120 away from the first component 110.Preferably, the leaves 115 are hinged, allowing for ease of coupling anddecoupling to the mating surface 125.

Although the Lightband eliminates the inherent danger of explosivesduring pre-launch assembly and testing, minimizes the shock effectsduring separation, and provides a connector component that is stiff,strong, and easy to use, it is fairly expensive to manufacture andassemble. An 8″ diameter Lightband, for example, may have as many as 11leaf elements and hinges that are machined from 0.5″ aluminum stock, andthe assembly procedure must conform to rigorous standards.

It would be advantageous to reduce the number and cost of parts used ina non-explosive connector assembly. It would also be advantageous toreduce the cost and complexity of the assembly process.

These advantages, and others, are achieved by creating a lockingcomponent that can be deformed and placed into a stable state that locksthe component into a mating component, and can easily be released fromthe deformed state, decoupling the two components. The locking componentmay include a central ring, a plurality of leaf elements arranged at theperimeter of the component, and a plurality of fins that extend outwardfrom the ring to the plurality of leaf elements. A rotation of the ringelement while the component is held stationary causes the fins to urgethe leaf elements toward the receiving surface areas and to subsequentlytension the leaf elements against surfaces on the mating component. Toreduce cost and complexity, the locking component is a metal, such astitanium, that can be formed using an additive manufacturing process,commonly termed a 3-D printing process.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in further detail, and by way of example,with reference to the accompanying drawings wherein:

FIGS. 1A-1B illustrate an example prior art non-explosive spacecraftconnection assembly.

FIG. 2 illustrates an example locking component of a connection assemblyin accordance with aspects of this invention.

FIG. 3 illustrates a coupling of the example locking component to amating component.

FIG. 4 illustrates a locking and release system for coupling anddecoupling the locking component and the mating component.

FIGS. 5 and 6 illustrate supplemental features of the locking componentand mating component.

FIG. 7 illustrates an example coupling system with supplementalfeatures.

FIG. 8 illustrates an example process for coupling two vehicles using aconnection assembly that includes an locking component that securelycouples the vehicles.

Throughout the drawings, the same reference numerals indicate similar orcorresponding features or functions. The drawings are included forillustrative purposes and are not intended to limit the scope of theinvention.

DETAILED DESCRIPTION

In the following description, for purposes of explanation rather thanlimitation, specific details are set forth such as the particulararchitecture, interfaces, techniques, etc., in order to provide athorough understanding of the concepts of the invention. However, itwill be apparent to those skilled in the art that the present inventionmay be practiced in other embodiments, which depart from these specificdetails. In like manner, the text of this description is directed to theexample embodiments as illustrated in the Figures, and is not intendedto limit the claimed invention beyond the limits expressly included inthe claims. For purposes of simplicity and clarity, detaileddescriptions of well-known devices, circuits, and methods are omitted soas not to obscure the description of the present invention withunnecessary detail.

In the interest of clarity and ease of understanding, the two elementsthat are to be coupled together by the connection assembly of thisinvention are termed “vehicles”, because at least one of these elementsmust be mobile. The term “vehicle” as used herein merely means astructure that is removable from another structure.

FIG. 2 illustrates an example locking component 210 and an examplemating component 220 of a connection assembly 200 in accordance withaspects of this invention. In a typical configuration, the locking 210and mating components will be coupled to vehicles (not shown) that areto be controllably coupled and de-coupled to/from each other. As in theLightband of FIG. 1A, the locking component 210 includes leaf elements215 that are designed to engage corresponding receiving surfaces 225 ina mating component 220 of the connection assembly 200. In this example,locking component 210 includes a core element 230, in this case a ringstructure, with fins 240 that extend outward from the core element 230to the leaves 215. The locking and mating components also includefeatures 290, such as bolt holes, that facilitate the fixed attachmentof the components 210, 220 to their respective vehicles (notillustrated).

As contrast to the Lightband of FIG. 1A, however, in accordance with anaspect of this invention, the locking component 210 may be acontinuously formed, or “integral” component that is created using 3-Dprinting technology. This integral locking component 210 includes theleaves 215, the core element 230, and the fins 240. It is estimated thatthe assembly cost for a coupling system using this integral lockingcomponent 210 will be at least an order of magnitude less than theassembly cost for the Lightband of FIG. 1A. Additionally, the materialcost and total manufacturing time can be expected to be reducedsignificantly, as detailed further below.

A 3-D printing process, also known as an additive manufacturing (AM)process, is any of various processes for making a three-dimensionalobject of a desired shape from a 3-D model or other electronic datasource, primarily through additive processes in which successive layersof material are laid down under computer control. In a preferredembodiment, the material that is successively laid down for the integrallocking component 210 may include Titanium (Ti), or a Titanium alloy,although other materials having high strength and high fracturetoughness, such as Aluminum, stainless steel, Inconel and berylliumalloys) may be used. Further, plastics such as nylon and ULTEM may beused when the separable vehicle is relatively light. A combination ofmaterials may also be used.

Any of a variety of techniques may be used to additively produce thelocking component 210, including, for example, electron-beam melting(EBM) selective laser melting (SLM), direct metal laser sintering(DMLS), selective laser sintering (SLS), and fused deposition modeling(FDM).

In operation as a coupling system, after fabricating the component 210,if the component 210 is held stationary while the core element 230 isrotated in a clockwise 250 direction (viewed from above), the fins 240will be urged outward, causing the leaves 215 to also be urged outward.This outward movement will cause the leaves 215 to contact the receivingsurfaces 225, and further clockwise 250 rotation will result incontinued pressure on the leaves 215, holding them in compressionagainst the surfaces 225.

In like manner, a counter-clockwise 260 rotation of the core element 230while the component 210 is held stationary will cause the fins 240 tomove inward. Because the fins 240 are coupled to, or integral with theleaves 215, this counter-clockwise 260 rotation will cause the leaves215 to be drawn inward, thereby disengaging the leaves 215 from thereceiving surfaces 225 on the mating component 220 of the connectionassembly 200.

As detailed further below, the leaves 215 of the component 210 may beformed such that in an “unloaded”, or “neutral”, or “minimal strainenergy” state, the leaves 215 are biased in the inward direction, suchthat a release of the tension on the core element 230 results in adisengagement of the leaves 215 from the receiving surfaces 225.Alternatively, the leaves 215 of the component 210 may be formed suchthat in an unloaded/neutral state, the leaves 215 are biased in theoutward direction. In this configuration, a release of the tension onthe core element 230 results in an engagement of the leaves 215 with thereceiving surfaces 225.

FIG. 3 illustrates a coupling of the example locking component 210 to amating component 220. As illustrated, the leaf element 215 includes apatterned surface 315 that engages a corresponding patterned receivingsurface 225. In this example, the pattern is a sawtooth pattern thatprovides interlocking lateral grooves that prevent separation of thesurfaces 315, 225 when the leaf elements 215 are urged outward to engagethe receiving surfaces 225 via the clockwise rotation 250 of the coreelement 230 of FIG. 2.

One of skill in the art will recognize that alternative patterns may beused, preferably based on the expected forces that will be experiencedwhen the components 210, 220 are deployed. For example, if thecomponents 210, 220 are expected to experience a rotational torque,vertical features may be included in the pattern to limit a rotationalshift of the surfaces 315, 225 relative to each other.

In an example embodiment, the thickness 330 of the Titanium elementsforming the leaf elements 215, fins 225, and core element (notillustrated in FIG. 3) is about 1.5 mm (0.06 inches), which allows for atorque of at least 800 in-lbs to be applied to the core element when theleaf elements 215 are engaged with their receiving surfaces 225, whichis sufficient to guarantee that surfaces 315 and 225 will remain coupledwhen subject to external loading.

In the design of the locking component 210 of FIG. 2, the “neutral”state of the component 210 with respect to the position/orientation ofthe leaves 215 determines the methods of coupling and decoupling thelocking component 210 and the mating component 220. That is, thelocation/orientation of the leaves 215 when no rotational force isapplied to the core element 230 defines the “neutral” state of component210. If the leaves 215 are extended outward in the neutral state, thecoupling of the components 210, 220 will require forcing the leaves 215inward (rotating the core element 230 counter-clockwise 260) while thereceiving areas 225 of the component 220 are placed atop the leaves 215of the component 210. Thereafter, releasing the inward force enables theleaves 215 to couple with the receiving surfaces 225. A reapplication ofthe inward force (rotating the core element 230 counter-clockwise 260)enables the leaves 215 to de-couple from the receiving surfaces 225.

If, on the other hand, the leaves 215 are contracted inward in theneutral state, the coupling of the components 210, 220 will requireforcing the leaves 215 outward (rotating the core element 230 clockwise250) after the receiving areas 225 of the component 220 are placed atopthe leaves 215 of the component 210. Thereafter, releasing the outwardforce enables the leaves 215 to decouple from the receiving surfaces225.

In like manner, if the neutral state situates the leaves 215 in anintermediate position between coupling and decoupling with the surfaces225, a rotational force will be required to either lock or unlock theleaves 215 to or from the receiving surfaces 225.

In a preferred embodiment for spacecraft coupling, because it isimportant to assure that the structures being coupled, such as a launchvehicle and its payload, are de-coupled upon deployment, the leaves arebiased toward the inward position in the neutral state. With this bias,the likelihood of the coupling being released in the event of a failureof some element of the coupling mechanism is increased. This inward biasof the leaves 215 also allows the leaves 215 to be disengaged from thereceiving surfaces 225 with minimal applied force, as detailed furtherbelow. In like manner, the rotation of the core element 230 to engagethe leaves 215 with the receiving surfaces 225 can easily be performedwhen the two components 210, 220 are being joined together (on theground). This inward orientation of the leaves 215 also allows for bothcomponents 210, 220 to be formed during the same printing process, asdetailed further below.

In other embodiments, such as the coupling of a highway vehicle and itsload, the leaves may be biased to the outward position in the neutralstate, to increase the likelihood that the load remains coupled to thevehicle in the event of a failure of the coupling mechanism.

FIG. 4 illustrates a locking and release system for coupling anddecoupling the locking component and the mating component. In thisexample, a capture bar 410 may be provided to lock the core element 230in a given rotational position when the core element is rotated toengage the leaves 215 and the receiving surfaces 225. For example, thecore element 230 may include a set of ratchet teeth (not illustrated)within a guide area 430, and the distal end of the capture bar mayinclude a feature that engages the ratchet teeth as the core element 230is rotated clockwise 250, preventing the core element 230 from rotatingcounter-clockwise 260.

In a preferred embodiment, the capture bar 410 includes an extension 420that extends perpendicular to the lateral extent of the capture bar 410and is secured to a lever 440 that extends parallel to the lateralextent of the capture bar 410. With this arrangement, the force exertedby the core element 230 to pull the capture bar 410 to the left istransferred to the lever 440, which opposes movement of the capture barto the left. In this manner, the core element 230 is held in thetensioned rotational position without an external force being applied.That is, in this configuration, the core element 230 is in amechanically stable state, wherein absent any external force to forcethe core element 230 out of this stable state, the core element 230 willremain in its tensioned state.

To place the core element 230 in an untensioned state, thus placing theleaves 215 in a release state, the lever 440 is rotatedcounter-clockwise 460. As the lever 440 is rotated, the capture bar 410is displaced from its stable state, allowing the core element 230 to‘unwind’ in the counter-clockwise 260 direction, pulling the leaves 215away from the surface areas on the mating component 220, therebyreleasing the mating component 220 from the locking component 210. In anexample embodiment, an electric motor (470 of FIG. 7) is used toinitiate the rotation of the lever 440, and the locking component 210includes a shelf or bracket 480 to accommodate the mounting of thismotor.

FIGS. 5 and 6 illustrate supplemental features of the locking component210 and mating component 220. As the term is used herein, a supplementalfeature is a feature that is not required for the function of couplingtwo vehicles together, but added to facilitate other functions.

In many applications, and in particular in spacecraft applications, thetwo vehicles being coupled by the locking component 210 and matingcomponent 220 need to be able to communicate. In the spacecraftapplication, for example, the launch vehicle may monitor the status ofthe payload, or at least monitor the integrity of the coupling of thepayload to the launch vehicle. This status information is typicallyrelayed back to the earth stations that are monitoring the launch.Additionally, the mechanism used to initiate the decoupling of thecomponents 210, 220 must receive a ‘deploy’ command from the launchvehicle at the appropriate time.

In the example embodiment of FIG. 5, the locking component 210 andmating component 220 include the housings 510 and optional brackets 520into/upon which items such as a separation switch 530 and electricalconnectors (not illustrated) may be installed. In like manner, thelocking component 210 may include channels or other supplementalfeatures that facilitate routing of electrical cables and the like.

Also in many applications, an active disengagement means isdesired/required to assure that the vehicles coupled to the lockingcomponent 210 and the mating component 220 are urged away from eachother.

In the example embodiment of FIG. 6, springs 610 are formed about theperimeter of the locking component 210. They may alternatively oradditionally be formed about the perimeter of the mating component 220.

In this example embodiment, both the locking component 210 and themating component 220 are formed during the same 3-D printing event.Accordingly, to enable the springs 610 to be in their expanded/neutralstate and still provide propulsion to separate the components 210, 220,the springs 610 need to extend beyond the position of the matingcomponent 220 in their neutral state. Accordingly, openings 620 areprovided in the mating component 220. These openings 620 willsubsequently be closed sufficiently to prevent the springs 610 fromextending beyond the component 220, thereby providing an expansive forcewhen the components 210 and 220 are mated to facilitate an urgedseparation of the vehicles coupled by the components 210, 220.

One of skill in the art will recognize that other supplemental featuresmay be included in the locking component 210 to facilitate operating,testing, and transporting the connector assembly 200 before theconnector assembly 200 is coupled to spacecraft and/or payload. Forexample, in its final configuration, the openings 620 will be closed,and the springs 610 will force the components 210, 220 apart. Thelocking component 210 and mating component 220 may include features 630that facilitate holding the components 210, 220 together when thesprings are compressed.

In like manner, the locking component 210 may include supplementalfeatures that facilitate testing of the coupling assembly, such asfeatures that enable rapid fastening of the locking component 210 to atest bed so that torque may be applied to the core element 230.Similarly, the locking component may include supplemental features thatfacilitate transport of the coupling assembly, such as a lifting eye.

FIG. 7 illustrates an example coupling system with such supplementalfeatures.

FIG. 8 illustrates an example process for coupling two vehicles using aconnection assembly that includes an integral locking component thatsecurely couples the vehicles.

At 810, a 3-D model of the locking component is created. This lockingcomponent includes a core element that, when torqued, tensions leafelements of a locking connection element to corresponding matingsurfaces of a mating connection element. In an alternative embodiment,the leaf elements are tensioned to the corresponding mating surfaceswhen negatively torqued (i.e. released).

At 820, this 3-D model is provided to an additive process machine,thereby enabling the additive process machine to produce thecorresponding integral locking component in a continuous manner, basedon the 3-D model.

At 830, other parts of the connection assembly are provided, and theconnection assembly is assembled. The assembled connection assembly istested and verified to conform to given specifications, at 840.

At 850, each of two elements of the assembled connection assembly isattached to one of two vehicles, the two vehicles are joined together,and the core element of the connection assembly is torqued to securelycouple the two vehicles.

In a preferred embodiment, the integral locking component 210 and matingcomponent 220 are fabricated using a single additive manufacturingprocess. It is significant to note that fabricating the integral lockingcomponent 210 and mating component 220 using the same 3-D printing eventprovides a number of advantages, compared to an individual fabricationof each of these components 210, 220.

In the case of the mating of the leaves 215 and the mating surfaces 225,the 3-D model that defines the combination of the two components 210,220, need merely indicate a space between these elements 215, 225 toassure that the leaves 215 and the surfaces 225 are aligned.

In like manner, as may be appreciated in FIG. 3, given a defined spacebetween the leaves 215 and the surfaces 225, and assuming that thesurfaces 225 are rigidly affixed to the component 220, theposition/orientation of the leaves 215 will be in the inwardorientation, such that the unloaded/neutral position/orientation of theleaves 215 will facilitate a ‘default’ disengaged state with regard tothe surfaces 225.

As will be recognized by one of skill in the art, during the additiveprocess there must be a continuous link among all of the elements of thedesired structure. In the case of a combination of the components 210,220, this continuous link may be provided by sacrificial links, or tabs(not shown) between the components 210, 220. These links may be providedfor example by a few tabs along the perimeters of the components 210,220 that couple the components 210, 220. The tabs are severed aftermanufacture to provide the individual components 210, 220.

Depending on the relative costs of material and processing, thesesacrificial tabs may be a different material than the primary materialof the components 210, 220. For example, the tabs may be a plastic orother material that can easily be removed from the basic materialcomprising the components 210, 220. In some embodiments, the materialused to couple the components 210, 220 during the 3-D printing processmay be a material that melts, dissolves, or otherwise decouples itselffrom the components 210, 220 given a particular control environment.

As noted above, the use of an integral locking component 210 providessignificant advantages compared to conventional coupling systems, suchas the Lightband of FIG. 1. Of particular note is the savings achievedwith regard to the assembly of the coupling system, as well as thereduction in material costs and other manufacturing tasks, such astesting.

The components of the Lightband of FIG. 1 are generally formed using asubtractive manufacturing process, such as precision milling of stockmaterial. The cost of the material that is removed to form thecomponents is included in the material cost of the component. In anadditive process, on the other hand, material is only used where it isrequired to form the component and any required sacrificial portions;generally, the cost of the sacrificial material in the additivemanufacturing process is substantially less than the cost of the removedmaterial in a subtractive manufacturing process.

The use of an integral locking component also reduces the time requiredto design, analyze, and test the coupling system. In the example of theLightband, hundreds of parts are used, and the interfaces between andamong these parts (e.g. hinges, bands, etc.) must be finely designed,analyzed, and tested. Typically, finite element analysis (FEA) is usedto assess the structural integrity of such a mechanical system, andmodeling the interfaces between and among elements of the system is achallenging task, often requiring extensive testing to verify the modelsused for these interfaces. With an integral locking component, suchmodeling is simplified, because there are no interfaces, per se, betweendifferent parts.

In like manner, because the integral locking component may generally beassumed to have a uniform consistency of material, and finite elementanalysis can verify the structural integrity of the design, testingafter manufacturing can be simplified. The aforementioned interfacesamong the elements of a mechanical system are generally the locale forfailures of the system, and the testing of the system must address allof these interfaces. With substantially fewer discrete elements in asystem with an integral locking component such as defined herein, thenumber of interfaces is substantially reduced, thereby simplifying thetesting process.

In like manner, the use of discrete parts complicates other analysis andtesting tasks, such as thermal and electrical analyses and subsequenttesting. The integral locking component, on the other hand, simplifiessuch analyses and test, thereby further reducing the cost to design,manufacture, and test the coupling system that uses the integral lockingcomponent. This reduction in the time required to design and analyze thecoupling system may also allow additional time to further optimize thedesign.

Additionally, the assembly of discrete parts, as in the Lightband ofFIG. 1, introduces a “tolerance buildup” and each part must be designedto strict tolerances to prevent this buildup from exceedingspecifications. The integral locking component, on the other hand, willnot experience this tolerance buildup, thereby further simplifying thedesign and testing of the coupling system.

The foregoing merely illustrates the principles of the invention. Itwill thus be appreciated that those skilled in the art will be able todevise various arrangements which, although not explicitly described orshown herein, embody the principles of the invention and are thus withinits spirit and scope. For example, the core element 230 is illustratedas having a circular inner section; one of skill in the art wouldrecognize that other shapes, such as a square or star shaped innersection may facilitate the torquing process using conventional tools. Inlike manner, the perimeter of the core element 230 and the perimeter ofthe arrangement of leaf elements 215 are illustrated as being circular.Although a circular arrangement facilitates a uniform application ofcompressive load to each leaf element 215, one of skill in the art wouldrecognize that other shapes may be used if such uniformity is notrequired, or if the fins 240 are suitably designed to provide asubstantially uniform compressive load with the leaf elements 215arranged in a non-circular shape. In like manner, the coupling of thecore element 230 and the fins 240 may be structured to reduce the torquerequired to rotate the core element 230. For example, the juncture ofeach fin 240 and the core element 230 may be formed using a material orshape that is more flexible than the remainder of the fin 240. These andother system configuration and optimization features will be evident toone of ordinary skill in the art in view of this disclosure, and areincluded within the scope of the following claims.

In interpreting these claims, it should be understood that:

a) the word “comprising” does not exclude the presence of other elementsor acts than those listed in a given claim;

b) the word “a” or “an” preceding an element does not exclude thepresence of a plurality of such elements;

c) any reference signs in the claims do not limit their scope;

d) any of the disclosed devices or portions thereof may be combinedtogether or separated into further portions unless specifically statedotherwise;

e) no specific sequence of acts is intended to be required unlessspecifically indicated; and

f) the term “plurality of” an element includes two or more of theclaimed element, and does not imply any particular range of number ofelements; that is, a plurality of elements can be as few as twoelements, and can include an immeasurable number of elements.

I claim:
 1. A connector assembly comprising: a locking component thatincludes: a core element situated at a center of the locking component;a plurality of leaf elements arranged at a perimeter of the lockingcomponent; a plurality of fins that extend outward from the core elementto the plurality of leaf elements; and a mating component that includesa plurality of receiving surface areas corresponding to each of theplurality of leaf elements; wherein: a rotation of the core elementwhile the locking component is stationary causes the fins to urge theleaf elements toward the receiving surface areas and to subsequentlyforce the leaf elements against the receiving surface areas.
 2. Theconnector assembly of claim 1, including a locking element thatmaintains the force on the leaf elements while in a mechanically stablestate.
 3. The connector assembly of claim 2, including a release elementthat places the locking component in a mechanically unstable state,causing the locking element to release the force on the leaf elements,thereby decoupling the locking and mating components.
 4. The connectorassembly of claim 3, wherein the locking element includes a lever, andthe release element places the locking component in the mechanicallyunstable state by rotating the lever.
 5. The connector assembly of claim4, wherein the release element includes an electric motor.
 6. Theconnector assembly of claim 1, wherein each leaf element includes anon-planar surface facing its corresponding receiving surface area, andthe corresponding receiving surface areas includes a complementarynon-planar surface for receiving the leaf elements.
 7. The connectorassembly of claim 6, wherein at least one of the non-planar surface orthe complementary non-planar surface includes one or more grooves. 8.The connector assembly of claim 1, wherein each of the locking andmating components include features that facilitate coupling the lockingand mating components to two vehicles that are to be coupled together.9. The connector assembly of claim 8, including the two components. 10.The connector assembly of claim 9, wherein the two components include aspacecraft delivery component and a payload component.
 11. The connectorassembly of claim 1, including springs that urge the mating componentaway from the locking component when the force on the leaf elements isreleased.
 12. The connector assembly of claim 1, wherein the coreelement, the leaf elements, and the fins are segments of a singleintegral component.
 13. The connector assembly of claim 12, wherein thesingle integral component is a printed component.
 14. The connectorassembly of claim 12, wherein the single integral component is a printedtitanium component.
 15. The connector assembly of claim 12, wherein thesingle integral component includes supplemental structures thataccommodate electrical components.
 16. The connector assembly of claim12, wherein the single integral component includes supplemental featuresthat facilitate routing of electrical cables.
 17. The connector assemblyof claim 12, wherein the single integral component includes supplementalfeatures that facilitate coupling of the locking and mating componentswithout urging the leaf elements toward the receiving surface areas. 18.The connector assembly of claim 12, wherein the single integralcomponent includes supplemental features that facilitate testing of theconnector assembly.
 19. The connector assembly of claim 12, wherein thesingle integral component includes supplemental features that facilitatetransport of the connector assembly.
 20. The connector assembly of claim12, including springs that urge the mating component away from thelocking component when the force on the leaf elements is released,wherein the springs are also segments of the single integral component.